Fabric with Flow Restricting Core

ABSTRACT

A stitched fabric including a barrier layer; a yarn stitched through and forming stitch holes in the barrier layer, and a foam core formed over the barrier layer. A melted portion of the barrier layer fills at least a portion of the stitch holes. The foam core is prevented from progressing further into the stitched fabric by the barrier layer. As such, the barrier layer is configured to control a depth to which the foam core penetrates into the stitched fabric. The foam core may be formed over at least a portion of the yarn. A second foam core may be formed on a side of the barrier layer opposite the foam core.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.62/779,824 filed Dec. 14, 2018 by Dustin English, et al., entitled“Fabric with Flow Restricting Core,” which is incorporated herein byreference as if reproduced in its entirety.

BACKGROUND

Controlling the depth to which foaming chemicals or coating materialspenetrate a fabric is difficult due to the nature of the foamingprocess. Indeed, foaming chemicals or coating materials often expand orflow in a non-uniform manner. As such, a fabric incorporating thesefoaming chemicals or coating materials may suffer from irregularitiessuch as, for example, changing thickness, an uneven look or feel, and soon.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, and theadvantages thereof, reference is now made to the following descriptionstaken in conjunction with the accompanying drawings, in which:

FIG. 1 is a cross section of an embodiment of an initial stage of astitched fabric having a barrier layer stitched through by a yarn.

FIG. 2 is a cross section of an embodiment of a stitched fabric having afoam core disposed over a barrier layer.

FIG. 3 is a cross section of an embodiment of a stitched fabric having afoam core formed from a foaming agent.

FIG. 4 is a cross section of an embodiment of a stitched fabric having asecond foam core formed from a second foaming agent.

FIG. 5 is a cross section of an embodiment of a composite barrier layersuitable for use in the fabrics of FIGS. 1-4.

FIG. 6 is an embodiment of a method of forming the stitched fabric ofFIG. 2.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The making and using of the presently preferred embodiments arediscussed in detail below. It should be appreciated, however, that thepresent disclosure provides many applicable inventive concepts that canbe embodied in a wide variety of specific contexts. The specificembodiments discussed are merely illustrative and do not limit the scopeof the disclosure.

Disclosed herein is a fabric or article incorporating or benefiting froma foam core. By constructing a soft, stretchable, lightweight knit witha foam core (e.g., closed cell aerogel foam core), an improved garmentor article (e.g., coats, jackets, hats, gloves, footwear, watch bands,bicycle frames, beverage coolers, etc.) with enhanced properties may beproduced.

Referring to FIG. 1, an embodiment fabric 100 in an initial stage isillustrated. The fabric 100 may have a variety of beneficial properties.For example, in an embodiment the fabric 100 is soft, stretchable, ableto wick away moisture, and so on. As shown in FIG. 1, in an embodimentthe fabric 100 in this initial stage includes a barrier layer 102 and ayarn 104.

In an embodiment, the barrier layer 102 is configured to inhibit fluidflow. In other words, the barrier layer 102 is generally liquidresistant or waterproof. Therefore, the barrier layer 102 functions todiscourage fluid flow through the fabric 100. In addition, in anembodiment the barrier layer 102 is also windproof, yet still permitsthe fabric 100 to be breathable. In other words, the barrier layer 102is able to block wind from undesirably passing through the fabric 100while still permitting moisture vapor generated by, for example, bodyheat to be dissipated.

Still referring to FIG. 1, the yarn 104 is stitched through the barrierlayer 102. In an embodiment the yarn 104 is a polyester orpolyester-blend yarn, a nylon or nylon-containing yarn, a carbon fiberyarn, or other type of yarn. The yarn 104 may be chemically or otherwisetreated to resist stains, repel moisture, resist flames, or provideother beneficial properties.

As shown, in an embodiment the yarn 104 is stitched through more than amajority (e.g., greater than 50%) of the barrier layer 102. In otherwords, the yarn 104 is stitched over a substantial portion of the lengthand width of barrier layer 102. Depending on how tightly the stitchingis performed, the yarn 104 may permit portions of the underlying barrierlayer 102 to be visible or may obscure all or a portion of theunderlying barrier layer 102.

In an embodiment, the fabric 100 of FIG. 1 is constructed by stitching apolyester yarn 104 through the barrier layer 102 such that the majorityof the surface area of the barrier layer 102 is covered. During thestitching process, the yarn 104 forms stitch holes 106 through thebarrier layer 102 as shown in FIG. 1. In some circumstances, it isdesirable to seal off or plug these stitch holes 106. As will be morefully explained below, some or all of the stitch holes 106 formed by theyarn 104 are partially or fully filled when the barrier layer 102 issufficiently heated. For example, the barrier layer 102 may be heated toa thermoplastic state, which allows a portion of the barrier layer 102to flow and plug a portion of the stitch holes 106 in the barrier layer102.

Referring now to FIG. 2, a fabric 200 including a barrier layer 202, ayarn 204, and a foam core 208 is illustrated. Similar to the fabric 100of FIG. 1, the fabric 200 includes stitch holes 206 that have beenpartially or fully filled after the barrier layer 202 is heated.However, the fabric 200 also incorporates the foam core 208 on one sideof the barrier layer 202. As shown, the barrier layer 202 controls thedepth to which the foam core 208 penetrates into the fabric 200. Forexample, the barrier layer 202 prevents the foam core 208 fromprogressing further downwardly into the fabric 200 as oriented in FIG.2. Indeed, by putting the barrier layer 202 (or other membrane) in thefabric 200 at the desired depth, the depth to which the foam core 208penetrates the fabric can be precisely controlled.

In an embodiment, the barrier layer 202 may support or include a radiantreflective film. That is, a radiant reflective film may be disposed upona surface of the barrier layer 202 or incorporated into the barrierlayer 202. In an embodiment, the radiant reflective film on or in thebarrier layer 202 prevents or inhibits radiant energy from entering anarticle (e.g., a beverage cooler). In an embodiment, the radiantreflective film prevents or inhibits radiant energy from exiting theinterior of an article (e.g., a beverage cooler).

In an embodiment, the barrier layer 202 is a non-woven fabric. In suchan embodiment, the yarn 204 is stitched through the barrier layer 202.However, the stitch holes 206 that are formed are not plugged by meltinga portion on of the barrier layer 202 as described elsewhere herein.

In an embodiment, a beverage cooler may be formed using a fabric 200containing a barrier layer 202 benefitting from a radiant reflectivefilm (e.g., a soft side beverage cooler). In an embodiment, the barrierlayer 202 is moisture vapor permeable. Therefore, any steam generated byhot items placed in the beverage cooler is allowed to escape. As such,the steam does not condense inside the beverage cooler, which helpskeeps the items therein both hot and dry.

In an embodiment, the foam core 208 comprises any structure havingpockets of gas trapped in a liquid or solid. In an embodiment, the foamcore 208 comprises a closed cell aerogel foam, a polyurethane foam(i.e., foam rubber), a polystyrene foam, a polyvinyl chloride (PVC)foam, and so on. In an embodiment, the foam core 208 has eitherhydrophobic or hydrophilic surfaces. In an embodiment, the foam core 208comprises a non-foaming coating (e.g., polyurethane).

In an embodiment, a stitched fabric (e.g., fabric 200) includes abarrier layer (e.g., barrier layer 202), a yarn (e.g., yarn 204)stitched through and forming stitch holes (e.g., stitch holes 206) inthe barrier layer, where a melted portion of the barrier layer fills atleast a portion of the stitch holes, and a coating (e.g., foam core 208,non-foaming coating, etc.) formed over the barrier layer. In anembodiment, the coating is prevented from progressing further into thestitched fabric by the barrier layer. In an embodiment, the coatingcomprises a polyurethane, another suitable polymer (e.g., Polycarbonate,Polyether-Polycarbonate, Polyether-Polyester, etc.), or a coatingcontaining or formed from a polymer resin. In an embodiment, the coatingis non-foaming. In an embodiment, the barrier layer supports or includesa radiant reflective film.

In an embodiment, a stitched fabric (e.g., fabric 200) includes anon-woven barrier layer (e.g., barrier layer 202), a yarn (e.g., yarn204) stitched through and forming stitch holes (e.g., stitch holes 206)in the non-woven barrier layer, and a foam core (e.g., foam core 208)formed over the non-woven barrier layer. In an embodiment, the non-wovenbarrier layer includes or supports a radiant reflective film. In anembodiment, the foam core is prevented from progressing further into thestitched fabric by the non-woven barrier layer. In an embodiment, thenon-woven barrier layer is configured to control a depth to which thefoam core penetrates into the stitched fabric.

In an embodiment, a stitched fabric (e.g., fabric 200) includes anon-woven barrier layer (e.g., barrier layer 202), a yarn (e.g., yarn204) stitched through and forming stitch holes (e.g., stitch holes 206)in the barrier layer, and a coating (e.g., foam core 208, non-foamingcoating, etc.) formed over the non-woven barrier layer. In anembodiment, the coating is prevented from progressing further into thestitched fabric by the barrier layer. In an embodiment, the coatingcomprises a polyurethane, another suitable polymer (e.g., Polycarbonate,Polyether-Polycarbonate, Polyether-Polyester, etc.), or a coatingcontaining or formed from a polymer resin.

Referring now to FIG. 3, in an embodiment the foam core 308 begins as afoaming agent 308′. As shown, the foam agent 308′ is applied over thebarrier layer 302, which has already been heated to close off the stitchholes 306. The foam agent 308′ is subjected to heat or some othercatalyst until it fully or sufficiently expands. As shown in FIG. 3, thefoam core 308 formed from the foam agent 308′ may completely cover theyarn 304 on one side of the fabric 300.

Referring now to FIG. 4, in an embodiment a second foam core 410 isformed on a side of the fabric 400 opposite the initially formed foamcore 408. The second foam core 410 begins as a foaming agent 410′. Thesecond foam core 410 may be the same as or different than the first foamcore 408. As shown, the foam agent 410′ is applied over the barrierlayer 402 on a side opposite the foam core 408. The barrier layer 402has already been heated to close off the stitch holes 406. The foamagent 410′ is subjected to heat or some other catalyst until it fully orsufficiently expands. As shown in FIG. 4, the foam core 410 formed fromthe foam agent 410′ may completely cover the yarn 404 on one side of thefabric 400. Thus, the fabric 400 may have two precisely controlled foamcores 408, 410.

In FIG. 5, a composite barrier layer 512 that may be used in the fabrics100-400 is illustrated. In an embodiment, the barrier layer 512comprises an adhesive 520 and an intermediate material 522 (e.g., aporous membrane or a non-porous film) as shown in FIG. 5. In anembodiment, the barrier layer 512 may include several adhesive 520layers and/or several intermediate layers 522.

A melting point of the adhesive 520 is generally lower than a meltingpoint of the intermediate material 522. Therefore, the adhesive 520 maybe melted without also melting the intermediate material 522. In otherwords, the adhesive 520 may be forced to flow through the application ofsufficient heat without flowing, or compromising the integrity of, theintermediate material 522.

In an embodiment, the melting point of the adhesive 520 may be betweenabout 140° C. to about 180° C. (about 284° F. to about 356° F.) whilethe melting point of the intermediate material 522 exceeds about 180° C.(about 356° F.). Where the adhesive 520 and the intermediate material522 have different distinct melting points as noted above, the barrierlayer 512 may be referred to as having an “A-B” type format. In anembodiment, the adhesive 520 is approximately two thousandths of an inch(i.e., 2 mils) and the intermediate material 522 is approximately onethousandth of an inch (i.e., 1 mil).

In general, the adhesive 520 is a thermoplastic, copolyamide, or othersuitably meltable type of material capable of bonding two layers offabric together. A variety of different adhesives 520 may be used in thebarrier layer 512. By way of example, the adhesive 520 may be ahigh-quality textile adhesive such a polyurethane adhesive film, anethylene-vinyl acetate, and the like. In an embodiment, the adhesive 520may be heat sensitive, pressure sensitive, or both.

The intermediate material 522 of the barrier layer 512 may be either amembrane or a film formed from a variety of different materials. In anembodiment, the intermediate material 522 is formed from polyurethane,polyester, urethane, polyether, polytetrafluoroethylene (PTFE), oranother polymer-based material. The intermediate material 522 may bemanufactured using, for example, an extrusion, a melt blowing, or anelectrospinning process.

As shown in FIGS. 1-4, the fabric 100-400 is free of any other layer(e.g., a face layer or an interior layer) disposed over the foam core208, 308, 408, 410 or over the exposed barrier layer 202, 302 (see FIGS.2-3). As such, the barrier layer 202-302, the yarn 204-304, and/or thefoam core 208, 308, 408, 410 are free from contact by another layer oneither side of the barrier layer 102-302 and/or foam core 208, 308, 408,410. In an embodiment, the foam core 308, the barrier layer 302, and theyarn 304 are free from contact by another layer as shown in FIG. 3. Evenso, in an embodiment other layers (e.g., a face layer, an interiorlayer, etc.) may be added to the fabrics.

In an embodiment, a resin or other coating chemistry may be used inplace of any of the foam cores disclosed herein. The resins may be usedin conjunction with, for example, carbon fibers to form the fabrics. Inan embodiment, the composite fabrics 100-400 with the foam cores arethermo-moldable.

In FIG. 6, a method 600 of forming the fabric 200 of FIG. 2 isillustrated. In step 602, a barrier layer 202 is provided. In step 604,a yarn 204 is stitched through the barrier layer and the barrier layer202 is heated as described herein to at least partially fill the stitchholes 206. In step 606, a foam core 208 is formed over the barrier layer202. In an embodiment, the barrier layer 202 and the foam core 208 aresubjected to heating at the same time. As such, the foam core 208 isproduced at the same time as the stitch holes 206 are closed off. In anembodiment, a second foam core (e.g., foam core 410) may be formed on anopposing side of the stitched fabric 200 as the barrier layer 202.

What is claimed is:
 1. A stitched fabric, comprising: a barrier layer; ayarn stitched through and forming stitch holes in the barrier layer,wherein a melted portion of the barrier layer fills at least a portionof the stitch holes; and a foam core formed over the barrier layer. 2.The stitched fabric of claim 1, wherein the foam core is prevented fromprogressing further into the stitched fabric by the barrier layer. 3.The stitched fabric of claim 1, wherein the barrier layer is configuredto control a depth to which the foam core penetrates into the stitchedfabric.
 4. The stitched fabric of claim 1, wherein the foam core isformed over at least a portion of the yarn.
 5. The stitched fabric ofclaim 1, wherein the foam core completely covers the yarn on one side ofthe stitched fabric.
 6. The stitched fabric of claim 1, wherein the foamcore abuts the barrier layer.
 7. The stitched fabric of claim 1, whereinthe foam core extends over an entire length and width of the barrierlayer.
 8. The stitched fabric of claim 1, wherein the foam corecomprises a polyvinyl chloride (PVC) or a polyurethane.
 9. The stitchedfabric of claim 1, wherein at least one surface of the foam core ishydrophobic or hydrophilic.
 10. The stitched fabric of claim 1, whereina second foam core is formed on a side of the barrier layer opposite thefoam core.
 11. The stitched fabric of claim 1, wherein a melted portionof the barrier layer entirely fills the stitch holes.
 12. The stitchedfabric of claim 1, wherein the barrier layer comprises a first materialwith a first melting point and a second material with a second meltingpoint lower than the first melting point.
 13. The stitched fabric ofclaim 1, wherein the yarn is one of a polyester yarn and a carbon fiber.14. The stitched fabric of claim 1, wherein the foam core comprises anexpanded foam agent.
 15. A method of forming a stitched fabric,comprising: stitching a yarn through and forming stitch holes in abarrier layer; melting a portion of the barrier layer to fill at least aportion of the stitch holes; and forming a foam core over the barrierlayer.
 16. The method of claim 15, further comprising forming the foamcore by expanding a foaming agent.
 17. The method of claim 15, furthercomprising forming the foam core by heating a foaming agent.
 18. Themethod of claim 15, further comprising preventing the foam core fromprogressing further into the stitched fabric using the barrier layer.19. The method of claim 15, further comprising forming the foam coreover the yarn projecting from the barrier layer on one side of thestitched fabric.
 20. The method of claim 15, further comprising formingthe foam core using a polyvinyl chloride (PVC).
 21. The method of claim15, further comprising melting the portion of the barrier layer toentirely fill the stitch holes.
 22. A stitched fabric, comprising: abarrier layer; a yarn stitched through and forming stitch holes in thebarrier layer, wherein a melted portion of the barrier layer fills atleast a portion of the stitch holes; and a coating formed over thebarrier layer.
 23. The stitched fabric of claim 22, wherein the coatingis prevented from progressing further into the stitched fabric by thebarrier layer.
 24. The stitched fabric of claim 22, wherein the coatingcomprises a polyurethane.
 25. The stitched fabric of claim 24, whereinthe coating is non-foaming.
 26. The stitched fabric of claim 22, whereinthe barrier layer supports or includes a radiant reflective film.
 27. Astitched fabric, comprising: a non-woven barrier layer; a yarn stitchedthrough and forming stitch holes in the non-woven barrier layer; and afoam core formed over the non-woven barrier layer.
 28. The stitchedfabric of claim 27, wherein the non-woven barrier layer includes orsupports a radiant reflective film.
 29. The stitched fabric of claim 27,wherein the foam core is prevented from progressing further into thestitched fabric by the non-woven barrier layer.
 30. The stitched fabricof claim 27, wherein the non-woven barrier layer is configured tocontrol a depth to which the foam core penetrates into the stitchedfabric.
 31. A stitched fabric, comprising: a non-woven barrier layer; ayarn stitched through and forming stitch holes in the non-woven barrierlayer; and a coating formed over the barrier layer.
 32. The stitchedfabric of claim 31, wherein the coating comprises a polyurethane.